I've got a 1989 Sundance Cameo with the Sentry 605 control system, with the plastic "Hi Flo" heater assembly. See attached diagram. It is leaking from the seam somewhere between part 4 (connector box) and part 8 (manifold).

I guess I'll start by trying a new gasket (part #5 in picture) and o-ring (part #7), since those seem to be the things which would fail and cause a leak. If those don't do the trick, my costs are going to quickly escalate.

Questions:

1) Is rebuilding this heater my only option? i.e. is it the only one that works with my otherwise functioning 605 system? Or is there a retrofit/replacement model out there meant to replace the plastic Hi Flo?

2) Is this a 'classic' issue with this model of heater, and if so what is the most likely fix?

Thanks,
Tim

opened up the heater finally. element, housing, manifold appear solid and not warped or cracked etc. it appears that the o-ring (#7) is pretty intact and that that it's the gasket (#5) that is shot. i am going to replace both and see what happens.

there was some strange black stuff inside the heater and it would be helpful if someone could identify it as either a) some sort of deposit or b) a burnt off layer of the inside of the plastic heater housing. either way i would be better off knowing what it is.

anyway, have a look at the pics and please let me know if you think my prognosis if off.

thanks,
tim w.

received and installed the rubber element gasket and o-ring yesterday. it appears to big heater leak has been solved. hooray!

Looks like my problem. Last December Circ pump died and froze pump 2. Replaced Circ pump and #2. Now my heater leaks. Going to order the gasket and O ring. How hard was it to replace?

I guess you remove the heater from the electrical panel to rebuild.

Sean
Maxxus 850